JP4161835B2 - Planning device, planning method and program for production quantity planning by product type - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a technique for creating a production number plan for each type of product. In particular, it is equipped with multiple parts production lines and multiple product production lines, supplying parts produced on one part production line to multiple product production lines, and combining products with different functions on the product production line The present invention relates to a technique for creating a production number plan for each type of product for a production system to produce. In this production system, a plurality of component types having the same function are prepared, a component type to be used is selected from among them, and a product type is created by changing the combination of the component types.
[0002]
The main terms used in this specification will be explained.
The production plan planned with this technology is not limited to the final plan. Includes production plan drafts that are drafted during the final stage of final production plan planning. If a production plan (or draft) can be drafted, the subsequent examination process is simplified, and a reasonable production plan can be obtained in a short period of time. In a large-scale production system, technology for drafting a production number plan is required.
A group of components having the same function is collectively referred to as the same functional component. Parts with different functions are called other functional parts. For example, a plurality of types of engine groups having different displacements are the same functional parts, and the transmission is another functional part.
There are multiple types of the same functional parts. If there are multiple types of engines with different displacements, there is a “type” for each displacement. If there is an automatic transmission and a manual transmission, there are two “types”. If there are 2WD drive parts and 4WD drive parts, there are two “types”.
Product types are classified by combinations of types for each functional component. For example, there are two types (A1, A2) in the first functional component, two types (B1, B2) in the second functional component, and two types (C1, C2) in the third functional component. If products are produced in all combinations, A1-B1-C1, A1-B1-C2, A1-B2-C1, A1-B2-C2, A2-B1-C1, A2-B1-C2, A2- There are 8 types of products, B2-C1 and A2-B2-C2. In this case, it may be different from the conventional product type. For example, even though it is understood by society that all products of A1-B1-C1 and A1-B1-C2 are the same type and have different specifications, it is assumed that the types are different in this specification. .
The combination of component types refers to a combination of component types for each functional component. In the above example, the first functional component is either A1 or A2, and there is no combination A1-A2. When a product requires three types of functions, since three types of functional parts are used, the product type is specified by a combination of three types of parts. In the case of the previous example, the type for the first functional component (A1 or A2), the type for the second functional component (B1 or B2), and the type for the third functional component (C1, C2 The combination of the part types is specified by any one).
A period is a period of a unit for managing the number of products and parts produced. The planning period refers to a period for creating a production number plan. One planning period may include a plurality of periods. For example, when a production number plan for one month is made in units of one day, the “period” is one day, and the “plan period” is one month.
[0003]
[Prior art]
For example, in a production department of a production company of automobiles, orders are received from sales departments in various places. The production department collects orders and arranges the number of orders by product type. Based on the number of orders for each product type, the production number plan for each product type will be drafted after taking into account restrictions such as the production capacity of the production plant. If a production plan that produces all of the ordered products cannot be created due to restrictions such as production capacity of the production plant, the types and numbers of products that cannot be produced are clarified and fed back to the sales department. The sales department refers to the feedback result and changes the number of orders for each product type. The sales department reviews sales policies and changes the number of orders so that the number of orders can be produced.
[0004]
In order to make a production number plan for each product type, it is necessary to consider the production capacity of the parts production line that produces the parts used for the target product type. There are multiple parts production lines and multiple product production lines, supplying parts produced on one part production line to multiple product production lines, and multiple parts of the same type used in one product production line When obtaining from the production line, depending on the combination of the parts production line and the product production line, the product production line orders the parts on the parts production line, produces the parts on the parts production line, and delivers the produced parts to the product production line. Since the lead time required to do so is different, it is not possible to study the production capacity of the parts production line with the lead time being uniform. When considering the production capacity of the parts production line, it is necessary to take into account the difference in lead time.
[0005]
Japanese Patent Application Laid-Open No. 2004-151561 discloses a technique for creating a product production number plan for a manufacturing system having a plurality of bases for producing parts or products. This technology considers the production capacity of parts production bases and the difference in lead times between parts production bases and product production bases based on product production requirement information, and how much and what kind of parts at which parts base. Calculate what to produce. From this calculation result, the production number plan for each base is drawn up.
Patent Documents 2 to 4 also disclose techniques for creating a production number plan for a product in consideration of parts used for the product.
[0006]
[Patent Document 1]
Japanese Patent Laid-Open No. 2000-10606
[Patent Document 2]
JP-A-9-81633
[Patent Document 3]
JP 2002-123310 A
[Patent Document 4]
JP-A-11-207574
[0007]
[Problems to be solved by the invention]
When there are a plurality of parts production lines and a plurality of product production lines, there are cases where parts produced on one part production line are supplied to a plurality of product production lines and used. For example, when A and B exist in the parts production line and a and b exist in the product production line, the parts produced in the part production line A are used in the product production lines a and b. The produced parts may be used in the product production lines a and b. In this case, there are a plurality of combinations of the parts production line and the product production line, and the lead time may be different for each combination. For example, 2 days from parts production line A to product production line a, 4 days from parts production line A to product production line b, 3 days from parts production line B to product production line a, products from part production line B The lead time may be different, such as 3 days until the production line b. In this case, it is necessary to consider whether or not the production capacity of the parts production line is sufficient for the required number of parts that differ from period to period. For example, for the part production line A, it is necessary to examine whether or not the part production capacity is sufficient for the required number of product production on the product production line a two days before the product production date. It is necessary to examine whether or not the parts production capacity is sufficient for the required number of products on the product production line b four days ago. In addition, for parts production line B, it is necessary to examine whether the parts production capacity is sufficient for the required number of products produced in product production line a three days before the product production date. It is necessary to examine whether or not the parts production capacity is sufficient for the required number of products in the product production line b. In particular, for the part production line B, if the part type required for the product production line a and the part type required for the product production line b are the same, these are totaled three days before the product production date. The parts production capacity must be examined for the required number of product production.
[0008]
As described above, many products are produced by combining functional parts. For example, when changing the combination of three types of functional parts, the product type to which A1-B1-C1 is attached and the product type to which A1-B1-C2 is attached are created separately. In this case, if the production of the product type produced by the combination of A1-B1-C1 from the production capacity of the third functional component C1 is less than the number of orders, if the type of the third functional component is changed from C1 to C2, In some cases, it is possible to produce a shortage of orders. The product type of A1-B1-C1 and the product type of A1-B1-C2 differ only in the type of the third functional part, and the types of other functional parts are common. High product. In this case, the ordered product type of A1-B1-C1 is not similar to the product number of A1-B1-C2 instead of satisfying the order number from the production capacity of the third functional component C1. It can be produced.
If the initial number of orders cannot be produced due to production capacity constraints, based on the initial number of orders, the content as close as possible to the contents of the order (the product type of A1-B1-C1 must be unable to be produced due to the lack of part C1. For example, it is possible to formulate a production number plan in which responding to orders with product types A1-B1-C2 similar to products that cannot be produced corresponds to the order contents). At this time, it is possible to devise a production number plan that does not reduce the total number of orders for the product types.
If production cannot be performed as ordered due to restrictions on parts production capacity, the sales department formulates a production number plan that is as close as possible to the contents of the order, and that the total number of production plans combined with the product type does not fall below the total number of orders. The sales department can refer to it and correct the number of orders for each product type. This is because the ordered products often include products ordered by the sales department, and the sales plan for each product type can often be adjusted up or down by changing the sales strategy.
When creating a production number plan that is as close as possible to the contents of the order and that the total production plan total of the product types does not become less than the total order number, the number of production plans (corresponding to the order) is limited due to production capacity constraints. Between parts production lines that reduce the following (or the required number of parts), or parts production lines that increase the number of production plans for substitute parts to more than the necessary number of production, and product production lines that use these parts The number of production plans for each part type must be adjusted to take into account the difference in lead times.
[0009]
If the number of production plans for one functional part of the combination of functional parts attached to a product is increased or decreased from the required number of production, the number of production plans for the product type that uses the functional part will also increase or decrease in conjunction. Become. In the above example, if the number of production plans for the third functional part C1 used for the A1-B1-C1 product is reduced to less than the required production number, the production plan number for the A1-B1-C1 product will be on the order. Will decrease to less than a few. In this case, it is also necessary to reduce the number of production plans for parts other than the third functional part C1 used in the A1-B1-C1 product, that is, the first functional part A1 and the second functional part B1. In addition, if the number of production plans for other types C2 of the third functional part C2 is increased by compensating for the reduction in the number of production plans for the third functional part C1, the product type that uses the third functional part C2 It is also necessary to increase the number of production plans. In the example, the first functional part type A1 and the second functional part type B1 that are used for the product types A1-B1-C2 by the number of production plans for the third functional part type C2 increased. It is necessary to increase the number of production plans.
In this case, the number of producible items of the first functional component type A1 and the second functional component type B1 must be increased. When the shortage of production capacity of the third functional part type C1 is compensated by increasing the production of the other third functional part type C2, the first product type that uses the third functional part type C2 to be increased is used. It is also necessary to consider the number of functional parts of type A1 and second functional parts of type B1 that can be produced.
Even in this case, it is necessary to take into account the difference in lead time between the parts production line that produces the parts that are reduced or increased in conjunction with the product production line that uses these parts.
[0010]
In Patent Documents 1 to 4, it is not considered that the lead time is different for each combination of the part production line and the product production line. In addition, considering the combination of types for each functional part attached to the product, if the number of production plans for one type of part is reduced to less than the required number, other parts used by the product in which the part is used It is also necessary to reduce the number of production plans in conjunction, and conversely, if the number of production plans for one type of part is increased beyond the necessary number of productions, It does not disclose that it is necessary to increase the number of parts production plans.
[0011]
The present invention comprises a plurality of parts production lines and a plurality of product production lines, supplies parts produced on one part production line to a plurality of product production lines, and produces a product by combining a plurality of parts having different functions. , A technology to create a production number plan for each product type for a production system that changes the combination of component types by selecting the component type to be used from among multiple component types having the same function. Propose.
In the present technology, it is considered that the lead time differs for each combination of the parts production line and the product production line. After that, it will be examined whether it is possible to respond to the order from the parts production capacity. If it is not possible to respond to the order from the parts production capacity, formulate a production number plan for each product type that approximates the contents of the order and that the total production plan total for the product type does not become less than the total order total for the product type. . At this time, the number of production plans for parts that are not excessive or deficient with respect to the number of production plans for products is drafted, and the number of production plans that satisfy the restriction on the number of products that can be produced for all necessary parts is drafted. Again, the number of parts production plans and the number of product production plans reflecting the difference in lead time for each combination of the parts production line and the product production line are obtained.
When the production number plan is established by this technology, it becomes possible to minimize the degree of loss of sales opportunities of products due to the limitation of the production capacity, thereby making it easier to achieve the sales target.
[0012]
[Means, actions and effects for solving problems]
The present invention includes the following production systems, that is, a plurality of parts production lines and a plurality of product production lines, and supplies parts produced on one part production line to a plurality of product production lines. A production system that creates product types by changing the combination of component types for each functional component by selecting the component type to be used from among multiple component types having the same function when producing a product by combining multiple different components. For this purpose, an apparatus for producing a production number plan for each type of product is provided.
This apparatus stores “order source / product type / order number” counting means for counting the number of orders by order source / product type, and a combination of part types used for the product type for each product type. “Product type / part type combination” storage means, and “Product production line / Product type / Production” that stores the product types that can be produced on each product production line, the number of products that can be produced, and the priority order. “Possible number / priority order” storage means, “part production line / part type / manufacturable”, which stores the types of parts that can be produced in each part production line, the number of parts that can be produced, and the priority order for the product production line Number / priority ”storage means and“ part production line / product production line / lead time ”storing the lead time from each part production line to each product production line And a 憶 means.
Further, the “order source / product type / number of orders” totaling means stores the order number for each order source / product type, and the “product production line / product type / manufacturable number / priority” storage means stores "Product production line / product type / necessary number of production" calculation means to calculate the required number of production for each product production line / product type based on the order of priority for the product production line, product type, possible production quantity and order source Based on the required number of products for each product production line / product type calculated by the “product production line / product type / number of required production” calculation means, the “product type / part type combination” storage means stores The combination of the product type and the part type, the part production line stored in the “part production line / part type / manufacturable number / priority” storage means, the part type, the number of producible products, and the product production line Refer to the ranking and the lead time from each part production line to each product production line stored in the "part production line / product production line / lead time" storage means, by period / part production line / part “Period / part production line / part type / necessary number of production” calculating means for calculating the required number of production by type is provided.
Furthermore, the required number of production by period / part production line / part type calculated by the “period / part production line / part type / production required number” calculation means is “part production line / part type / number of production possible / Reduce the number of production plans for parts types that exceed the production capacity for each part type stored in the "priority" storage means to less than the production capacity and respond to the reduced period within the number of reductions. The number of production plans for each part / part production line / part type is calculated by increasing the number of production plans for other part types of the same functional part within the range of production possible during A part production line / part type / number of production plans "calculating means is provided.
In this "period / part production line / part type / production plan number" calculating means,
(1) Reduced the number of production plans for the part types of other functional parts included in the product type, which includes the part type whose production plan number has been reduced from the required number of products in the "product type / part type combination" In the period corresponding to the period, decrease in conjunction,
(2) Increased the number of production plans for the part types of other functional parts included in the product type, which includes the part type whose production plan number is increased from the required number of productions in the "product type / part type combination" In a period corresponding to the period, interlocking adjustment means for executing a process of interlockingly increasing the maximum number of parts that can be produced on the part production line that produces the part type is added.
Further, based on the number of production plans by period / part production line / part type calculated by the “period / part production line / part type / number of production plans” calculation means, “product type / part type combination” storage means Refers to the combination of the product type and the part type that is stored in the product, and the lead time from each part production line to each product production line stored in the “part production line / product production line / lead time” storage means. Thus, a “product type / number of production plans” calculating means for calculating the number of production plans for each product type is provided.
[0013]
The “order source / product type / order number” counting means totals the number of orders by order source / product type. FIG. 14 (1) illustrates the number of orders by order source / product type, which are tabulated based on orders sent from the sales department. In this example, the number of orders is tabulated daily (by period), the number of orders from the order source a is 40 on the N day, 40 on the N + 1 day, and the order number from the order source b is the product type. β is 60 on the N day, 60 on the N + 1 day, the total number of orders on the N day is 100, and the total number of orders on the N + 1 day is 100. Here, N day or N + 1 day, which means the next day, refers to the future rather than the aggregation date, and the order source designates the future date and designates the number of products to be obtained on that day.
[0014]
The “product type / part type combination” storage means stores a combination of part types used for each product type. FIG. 14B illustrates a combination of a product type and a component type. The product type α1 includes a component of type E1 for the functional component E, a component of type M1 for the functional component M, and a functional component P. Is assembled by combining parts of type P1. In the product type α2, a part of type E2 is attached to the functional part E, a part of type M2 is attached to the functional part M, and a part of type P1 is attached to the functional part P.
[0015]
The “product production line / product type / manufacturable number / priority order” storage means stores the product type that can be produced in the product production line, the number of producible products, and the priority order for each product production line. FIG. 14 (3-1) illustrates the correspondence between the product production line, the product types that can be produced on the product production line, the number of products that can be produced, and the priority order for the order source. The product types that can be produced in the product production line La are α1 and α2, the number of products that can be produced is 30, the priority for the order source a is first, and the priority for the order source b is second. Is illustrated. In this case, it is understood that the product ordered from the order source “a” should be preferentially produced on the product production line La having the first priority. When the product ordered from the order source b cannot be produced on the product production line having the first priority, it is understood that the product should be produced on the product production line La having the second priority. . Similarly, the product types that can be produced in the product production line Lb are α1 and α2, the number of products that can be produced is 30, the priority for the order source b is first, and the priority for the order source a is second. It is exemplified. The order of priority for the order source is determined by conditions such as the short time required to deliver the product from the product production line to the order source and the low transportation cost. In this example, the production possible number is shown by day (by period).
The “part production line / part type / manufacturable number / priority order” storage means stores the part type that can be produced in the part production line, the number that can be produced, and the priority order for the product production line for each part production line. 15 (1-1), (2-1), and (3-1) show the correspondence between the part production line, the part types that can be produced on the part production line, the number of products that can be produced, and the priority order for the product production line. Illustrated. (1-1) exemplifies a part production line capable of producing a functional part E, the part type that can be produced in the part production line LA is E1, the number of products that can be produced is 50, and the product production line La It is exemplified that the priority order for is the first place and the priority order for the product production line Lb is the second place. Similarly, the part type that can be produced in the part production line LB that can produce the functional part E is E2, the number that can be produced is 50, the priority for the product production line Lb is first, and the product production line La It is exemplified that the priority order for is 2nd. (2-1) exemplifies a part production line capable of producing a functional part M, the part type that can be produced in the part production line LC is M1, the number of products that can be produced is 60, and the product production line La It is exemplified that the priority order for is the first place and the priority order for the product production line Lb is the second place. The type of parts that can be produced on the parts production line LD capable of producing the functional parts M is M2, the number that can be produced is 60, the priority for the product production line Lb is first, and the priority for the product production line La. Is illustrated in the second place. (3-1) exemplifies a part production line capable of producing a functional part P. The part type that can be produced in the part production line LE is P1, the number of products that can be produced is 100, and the product production line La It is exemplified that the priority order for is the first place and the priority order for the product production line Lb is the second place. Priorities for the product production line are determined by conditions such as a short lead time from the part production line to the product production line. Also in this example, the number of products that can be produced is shown by day (by period).
14 (3-1) and FIGS. 15 (1-1), (2-1), and (3-1), it is assumed that the number of products that can be produced for each product type and part type does not vary. However, the number of products that can be produced by day / product type or by day / part type may vary depending on changes in production facilities, the number of workers, work hours, and the like.
[0016]
The “part production line / product production line / lead time” storage means stores the lead time from each part production line to each product production line. In FIG. 14 (4), for example, the lead time from the parts production line LA to the product production line La is 3 days, and the lead time from the parts production line LA to the product production line Lb is 4 days. ing. Similarly, lead times from each part production line to each product production line are shown.
[0017]
The “product production line / product type / necessary number of production” calculation means is, for example, the number of orders by order source / product type shown in FIG. 14 (1) and the product production shown in (3-1). Based on the priority for the line, the product type, the number of products that can be produced, and the order source, the required production number for each product production line / product type is calculated as shown in (3-2).
In the product production line La, the product type α1 ordered from the order source “a” having the highest priority is preferentially produced, but cannot be produced beyond the production possible number. Therefore, it is calculated that 30 product types α1 need to be produced on N days and 30 product types α1 on N + 1 days. The ten product types α1 that cannot be produced on the product production line La with the first priority must be produced on the product production line Lb with the second priority on the order source a. Therefore, in the product production line Lb, it is calculated that it is necessary to produce 10 product types α1 on N days and 10 product types α1 on N + 1 days. In the product production line Lb, the product type α2 ordered from the order source b with the highest priority is preferentially produced, but cannot be produced beyond the production possible number. Therefore, it is calculated that 30 product types α2 need to be produced on N days and 30 product types α2 on N + 1 days. Thirty product types α2 that cannot be produced on the product production line Lb with the first priority for the order source b need to be produced on the product production line Lb with the second priority for the order source b. Therefore, in the product production line Lb, it is calculated that it is necessary to produce 30 product types α2 on N days and 30 product types α1 on N + 1 days.
[0018]
The “period / part production line / part type / required number of production” calculation means is based on, for example, the required production quantity by product production line / by product type shown in FIG. 14 (3-2). The combination of the product type and the part type shown in FIG. 15, the part production line, the part type, the number of products that can be produced, and the product production line shown in FIGS. 15 (1-1), (2-1), and (3-1). 15 (1-2), (2-2), and (3-2) with reference to the priority order for each and the lead time from each part production line to each production line shown in FIG. 14 (4). ), The required number of production for each period / part production line / part type is calculated. For example, in FIG. 14 (4), since the lead time from the parts production line LA to the product production line La is 3 days, the product production line La is produced 3 days before the product production line La is produced. It is calculated that the part type E1 needs to be produced. In order to produce 30 product types α1 on the N day in the product production line La, 30 parts types E1 are produced on the N-3 day in the part production line LA as illustrated in FIG. 15 (1-2). It is calculated that it needs to be done. Similarly, since the lead time from the part production line LA to the product production line Lb is 4 days, the part kind E1 is produced on the part production line LA four days before the product kind α1 is produced on the product production line Lb. It is calculated that it is necessary to keep. In order to produce 10 product types α1 on the N day in the product production line Lb, as shown in FIG. 15 (1-2), 10 part types E1 are produced on the N-4 day in the part production line LA. It is calculated that it needs to be done.
The same algorithm shows that in order to produce products in each product production line, it is necessary to produce which part type in which part production line in which period. It is possible to calculate the required number of production by part type. 15 (2-2) and (3-2) also calculate the required number of production by period / part production line / part type.
[0019]
The “period / part production line / part type / number of production plans” calculation means is, for example, for each period / part production line shown in FIG. 15 (1-2), (2-2), (3-2). The required number of production by part type exceeds the production possible number by part type shown in FIGS. 15 (1-1), (2-1), and (3-1). Reduce to: For example, in (1-2), the total required number of parts type E2 for N-3 days is 60 (the underline of the broken line is given), and the possible number of production shown in (1-1) 50 has been exceeded. In this case, as shown in FIG. 16 (1), the production plan number of the part type E2 is reduced to 50 which can be produced (the broken line is underlined). In this example, according to the proportional distribution of the production requirement number (30) for the product production line La and the production requirement number (30) for the product production line Lb shown in FIG. The number of production plans for the production line is reduced.
At the same time, the “period / part production line / part type / number of production plans” calculation means calculates other part types in the period corresponding to the reduced period (N-3 days) within the range of the above-mentioned reduction number of 10. The production plan number of E1 is increased within the range of 50 of the production possible number. Here, the period during which the part type E2 produced in the parts production line LB in the reduced period (N-3 days) is used in the product production line La is N + 1 days, and is used in the product production line La on N + 1 days. The part type E1 to be produced on the parts production line LB is N-2 days. The N-2 days is a period corresponding to the decreased period (N-3 days). Further, the period during which the part type E2 produced in the parts production line LB is used in the product production line Lb in the reduced period (N-3 days) is N days, and is used in the product production line Lb on the N day. It is N-4 days that the part type E1 is produced in the parts production line LA. This N-4 days is a period corresponding to the reduced period (N-3 days). Therefore, for the part type E1, the amount used on the product production line La is increased on the N-2 day, and the amount used on the product production line Lb is increased on the N-4 day. In FIG. 16 (1), the part type E2 has decreased in the corresponding period between the production required number for the product production line La and the production required number for the product production line Lb shown in FIG. 15 (1-2). It is increased by the amount (circled). As a result, in FIG. 16 (1), the part used on the product production line La is 35 on the N-2 day, and the part used on the product production line Lb is increased to 15 on the N-4 day. In any period, the number is less than the number of parts E1 that can be produced, and the number of production plans that can be executed.
[0020]
An interlock adjustment unit is added to the “period / part production line / part type / number of production plans” calculation unit. This linked adjustment means, for example, (1) Parts of other functional parts included in the product type α2 including the part type E2 in which the number of production plans is reduced from the required number of productions in the “product type / part type combination” The number of production plans of types M2 and P1 is decreased in conjunction with the decreased number in the period corresponding to the decreased period. As shown in FIG. 16 (2), out of the number of production plans for the part type M2, the amount used in the product production line La is reduced to 25 on the N-3 day of the corresponding period and used in the product production line Lb. The amount to be reduced is reduced to 25 on the N-3 day of the corresponding period (the dotted underline is given). In (3), the part used in the product production line La is reduced to 55 on the N-2 day of the corresponding period out of the number of production plans for the part type P1, and the part used in the product production line Lb. Is reduced to 35 on the N-4 day of the corresponding period (however, the decrease is offset by the following increase process, and the number does not change).
At the same time, (2) the component types M1 and P1 of other functional components included in the product type α1 included in the “product type / part type combination” including the part type E1 in which the number of production plans is increased from the required number of productions. In the period corresponding to the increased period, the number of production plans is increased in conjunction with the maximum number of parts that can be produced on the part production line. As shown in FIG. 16 (2), the part used in the product production line La out of the number of production plans for the part type M1 is increased to 35 on the N-2 day of the corresponding period and used in the product production line Lb. The amount to be increased is increased to 15 on the N-4 day of the corresponding period (circled). In (3), the part used in the product production line La in the production plan number of the part type P1 is increased to 60 on the N-2 day of the corresponding period, and the part used in the product production line Lb. Is increased to 40 on N-4 days of the corresponding period.
Since the part P1 is commonly used for the product type α2 that reduces production and the product type α1 that increases production compared to the number of orders, the number of production plans is reduced in conjunction with the production reduction of the product type α2 (part production at this time) The number of production plans for the product production line La on the N-2 day of the line LE is reduced by 5 to 55, and the number of production plans for the product production line Lb on the N-4 day is reduced by 5 to 35) The number of production plans is increased in conjunction with the increase in production of the product type α1 (At this time, the number of production plans for the product production line La on the N-2 day of the parts production line LE is increased by 5 to 60, The number of production plans for the N-4 day product production line Lb is increased by 5 to 40). Comparing FIG. 15 (3-1) and FIG. 16 (3), the decrease and the increase are offset and do not change.
[0021]
The “product type / number of production plans” calculation means, for example, is based on the number of production plans by period / part production line / part type shown in FIGS. 16 (1), (2), (3). The number of production plans for each product type is calculated with reference to the combination of product type and part type shown in 2) and the lead time from each part production line to each product production line shown in FIG.
The calculation result is illustrated in FIG. As shown in FIG. 16 (1), 35 part types E1 are produced on the N-2 day on the parts production line LA, so that they are used on the product production line La on the N + 1 day from the lead time of FIG. 14 (4). I understand that Since 35 part types M1 are produced on the N-2 day on the parts production line LC, it can be seen from the lead time in FIG. 14 (4) that they are used on the product production line La on the N + 1 day. Since 60 part types P1 are produced on the N-2 day on the parts production line LE, it can be seen from the lead time in FIG. 14 (4) that they are used on the product production line La on the N + 1 day. Producing 35 product types α1 on N + 1 day on product production line La using 35 P1 out of 35 E1 and 35 M1 and 60 P1 used on product production line La on N day Is calculated. Similarly, since the part production line LB produces 25 part types E2 for the product production line La on the N-3 day, it is used on the product production line La on the N + 1 day from the lead time of FIG. 14 (4). I understand that. Since 25 part types M2 are produced on the N-3 day on the parts production line LD, it can be seen from the lead time of FIG. 14 (4) that they are used on the product production line La on the N + 1 day. Since 60 parts P1 are produced on the N-2 day on the parts production line LE, it can be seen from the lead time in FIG. 14 (4) that they are used on the product production line La on the N + 1 day. Producing 25 product types α2 on N + 1 day on product production line La using 25 P1 out of 25 E5, 25 M1 and 60 P1 used on product production line La on N + 1 day Is calculated. It is calculated that the product production line La is planned to produce 35 product types α1 and 25 product types α2 every N + 1 days.
Similar calculations can be performed for the product production line Lb. As shown in FIG. 16 (1), the part production line LA produces 10 part types E1 for the product production line Lb on the N-3 day. Therefore, from the lead time of FIG. It can be seen that it is used in the production line Lb. Since the part production line LC produces 10 part types M1 for the product production line Lb on the N-3 day, it can be seen from the lead time in FIG. 14 (4) that it is used on the product production line Lb on the N + 1 day. . Since the part production line LE produces 40 part types P1 for the product production line Lb on the N-3 day, it can be seen from the lead time in FIG. 14 (4) that it is used on the product production line Lb on the N + 1 day. . Using 10 E1, 10 M1 and 10 P1 out of 40 P1 used in the product production line Lb on the N + 1 day, produce 10 product types α1 on the N + 1 day on the product production line Lb. Is calculated. Similarly, since part type E2 is produced 30 times for product production line Lb on part N-2 on part production line LB, it is used on product production line Lb on day N + 1 from the lead time of FIG. 14 (4). I understand that. Since 30 part types M2 are produced on the N-2 day on the parts production line LD, it can be seen from the lead time in FIG. 14 (4) that they are used on the product production line Lb on the N + 1 day. Since 40 parts P1 are produced on the N-3 day on the parts production line LE, it can be seen from the lead time in FIG. 14 (4) that they are used on the product production line Lb on the N + 1 day. Producing 30 product types α2 on N + 1 day on product production line Lb, using 30 P1 of 30 E2 and 30 M2 and 40 P1 used on product production line Lb on N + 1 day Is calculated. It is calculated that the product production line Lb is planned to produce 10 product types α1 and 30 product types α2 every N + 1 days.
Eventually, on N + 1 day, 35 product types α1 and 25 product types α2 will be produced on the product production line La, and 10 product types α1 and 30 product types α2 will be produced on the product production line Lb. In addition, it is calculated that 45 product types α1 and 55 product types α2 are produced.
The production plan numbers of the product type α1 and the product type α2 are changed from the respective order numbers, but the total production plan number of the product type α1 and the product type α2 is 100, which is the same as the total order number.
[0022]
As described above, the production number planning device for each type determines whether or not the product type requested in the order can be produced in consideration of the difference in lead time for each combination of the parts production line and the product production line. consider. In addition, a production number plan for each product type that does not reduce the total number of orders of the total product types within the range of the number of types that can be produced for each of the plurality of functional parts attached to the product is devised.
[0023]
The “order source / product type / number of orders” counting means recalculates the number of orders by order source / product type every predetermined period,
The “Product Production Line / Product Type / Production Required Number” calculation means recalculates the production required number for each product production line / product type for each predetermined period,
The number of production plans by product production line for product types that use part types whose required number of production exceeds the number that can be produced is calculated this time, and the number of production plans by product production line / product type calculated previously. The ratio of difference between the required number of production by product production line / product type is reduced from the required number of production by product production line of the product type according to the ratio of total difference ratio of all product production lines. "Product production line / number of production plans" reduction adjustment means to be added,
The “product type / production plan number” calculation means preferably recalculates the production plan number for each product type every predetermined period.
For example, the order number for N days after several months may be updated every predetermined period (daily, weekly, monthly) and sent from the sales department. This is because the sales plan (demand forecast) of the sales department is updated each time an actual customer order is confirmed in daily sales operations, and the number of orders based on the latest sales plan is sent. The “order source / product type / number of orders” counting means recalculates the number of orders for each N product types based on the latest number of orders sent every predetermined period. In the next predetermined period, based on the latest number of orders sent in the predetermined period, the number of orders for each N product types can be updated and recalculated. Accordingly, the “product production line / product type / required number of production” calculation means can recalculate the required production number for each product production line / product type for each predetermined period.
In this case, the number of production plans for each product production line of the product type that uses a part type whose required number of production exceeds the production possible number is calculated as the number of production plans for each product production line / product type calculated previously. Depending on the ratio of the difference between the required number of production by product production line / product type calculated this time to the total of the difference ratio of all product production lines, production by product production line for that product type is necessary. It is preferable to add a “product production line / production plan number” reduction adjusting means to reduce the number from the number.
For example, let us consider a case where the number of production plans for the product production line La and the product production line Lb using the part type E1 is reduced when the required number of parts type E1 exceeds the production possible number by 10. In this case, if the number of production plans of the product type α1 of the product production line La calculated last time is 60 and the number of production plans of the product type α1 of the product production line La calculated this time is 40, the difference The ratio is 60-40 / 60≈0.33. Further, if the number of production plans of the product type α1 of the product production line Lb calculated last time is 80 and the number of production plans of the product type α1 of the product production line Lb calculated this time is 60, the difference ratio Is 80-60 / 80 = 0.25. The excess 10 of the part type E1 is reduced according to the ratio of the difference ratio 0.33 of the product production line La and the difference ratio 0.25 of the product production line Lb to the total. The ratio occupied by the difference ratio of the product production line La is 0.33 / 0.33 + 0.25≈0.57, and the ratio occupied by the difference ratio of the product production line Lb is 0.25 / 0.33 + 0.25≈0. 43. Accordingly, the production plan number of the product type α1 of the product production line La is decreased by 0.57 × 10≈6, and the production plan number of the product type α1 of the product production line Lb is decreased by 0.43 × 10≈4.
Based on this result, it is preferable that the “product type / production plan number” calculating means is updated every predetermined period to calculate the production plan number for each product type.
The number of production plans calculated last time is based on the latest number of orders in a predetermined period closest to this time. Based on the number of production plans for which the past trend that is closest to this time is known, the rate of reduction of the number of production plans for each product production line can be calculated to calculate the number of reductions that is as realistic as possible.
[0024]
The number of production plans for each product production line of a product type that uses a part type for which the required number of production exceeds the number that can be produced is the number of production plans for each product production line of the product type that uses that part type. According to the ratio of the total production requirement, reduce the difference between the production requirement number of the relevant part type and the production plan number from the production requirement number of the product type by the product production line. It is preferable to add means for reducing the “planned number of production”.
For example, let us consider a case where the number of production plans for the product production line La and the product production line Lb using the part type E1 is reduced when the required number of parts type E1 exceeds the production possible number by 10. In this case, if the number of production plans of the product type α1 of the product production line La is 40, the part type E1 used in the product production line La is 40. If the production plan number of the product type α1 in the product production line Lb is 60, the part type E1 used in the product production line Lb is 60. Since the total necessary number of production of the part type E1 is 40 + 60 = 100, the proportion of the part type E1 used in the product production line La is 40/100 = 0.4, and the part type E1 used in the product production line Lb The ratio occupied by is 60/100 = 0.6. Therefore, the production plan number 40 of the product type α1 of the product production line La is reduced by 0.4 × 10 = 4, and the production plan number 60 of the product type α1 of the product production line Lb is reduced by 0.6 × 10 = 6. Let
The proportion of the part types required in the product production line to the total required number of production by part type can be considered as a contribution rate to the part type. Based on this contribution rate, by finding the ratio to reduce the number of production plans for each product production line, it is possible to maintain the contribution rate of the required number of production by product production line / product type calculated at the beginning. it can.
[0025]
According to the present invention, a plurality of parts production lines and a plurality of product production lines are provided, parts produced on one part production line are supplied to a plurality of product production lines, and a product is produced by combining a plurality of parts having different functions. A method for creating a production number plan for each product type has been created for a production system in which a product type is created by changing a combination of component types by selecting from a plurality of component types having the same function. This method is performed by the computer in the following steps:
・ Aggregating the number of orders by order source / product type,
・ Reading the combination of parts types used for each product type by product type;
The process of reading the product types that can be produced on each product production line, the number of products that can be produced, and the priority order for the order source,
・ Reading the types of parts that can be produced in each part production line, the number of products that can be produced, and the priority order for the product production line;
・ Reading the lead time from each part production line to each product production line;
A process for calculating the number of orders required for each product production line / product type based on the number of orders for each order source / product type, the product production line, the product type, the number of products that can be produced, and the priority for the order source; ,
・ Based on the required number of production by product production line / product type, the combination of product type and part type, part production line, part type, number of products that can be produced, priority for product production line, and each part production line With reference to the lead time to the product production line, the process of calculating the required number of production by period / part production line / part type,
・ The number of production required by the period / part production line / part type exceeds the production plan number of the part type that exceeds the production possible number by the part type, and within the range of the reduction number. In the period corresponding to the decreased period, the production by period / part production line / part type is increased by increasing the production plan number of other part types of the same functional part within the range of possible production. A process for calculating the number of plans;
-Based on the number of production plans by period / part production line / part type, refer to the combination of product type and part type, and the lead time from each part production line to each product production line. And a process for calculating the number of production plans for
-In the process of calculating the number of production plans by period / part production line / part type,
(1) A period corresponding to the period when the number of production plans for the part type of other functional parts included in the product type includes the part type whose production plan number is reduced from the required number of productions in the combination of the part type. In conjunction with,
(2) A period corresponding to the increased period of the number of production plans for the part types of other functional parts included in the product type that includes the part type with the number of production plans increased from the required number Then, a process of increasing the number of parts that can be produced on the part production line in association with each other is executed.
[0026]
In addition, according to the present invention, a plurality of parts production lines and a plurality of product production lines are provided, parts produced in one part production line are supplied to a plurality of product production lines, and a product is produced by combining a plurality of parts having different functions. In addition, a program for creating a production number plan for each product type was created for a production system that creates a product type by changing the combination of the component types by selecting from a plurality of component types having the same function. It was done. This program performs the following processing on the computer:
・ Aggregating the number of orders by order source / product type,
・ Reading the combination of parts types used for each product type
・ Processing to read the product types that can be produced on each product production line, the number of products that can be produced, and the priority order for the order source,
・ Reading the types of parts that can be produced in each part production line, the number of parts that can be produced, and the priority order for the product production line;
・ Process to read the lead time from each part production line to each product production line,
A process for calculating the number of orders required for each product production line / product type based on the number of orders for each order source / product type, the product production line, the product type, the number of products that can be produced, and the priority for the order source ,
・ Based on the required number of production by product production line / product type, the combination of product type and part type, part production line, part type, number of products that can be produced, priority for product production line, and each part production line With reference to the lead time to the product production line, the process of calculating the required number of production by period / part production line / part type,
・ The number of production required by the period / part production line / part type exceeds the production plan number of the part type that exceeds the production possible number by the part type, and within the range of the reduction number. In the period corresponding to the decreased period, the production by period / part production line / part type is increased by increasing the production plan number of other part types of the same functional part within the range of possible production. Processing to calculate the number of plans;
-Based on the number of production plans by period / part production line / part type, refer to the combination of product type and part type, and the lead time from each part production line to each product production line. Process to calculate the production plan number of
・ In the process of calculating the number of production plans by period / part production line / part type,
(1) A period corresponding to the period when the number of production plans for the part type of other functional parts included in the product type includes the part type whose production plan number is reduced from the required number of productions in the combination of the part type. In conjunction with,
(2) A period corresponding to the increased period of the number of production plans for the part types of other functional parts included in the product type that includes the part type with the number of production plans increased from the required number In FIG. 5, the process of increasing the number of parts that can be produced on the part production line is executed in conjunction with the upper limit.
[0027]
In the production plan planning method for each type of this product and the program for that, consider whether or not the product type requested in the order can be produced considering the lead times that differ for each combination of parts production line and product production line To do. In addition, it is possible to formulate a production number plan for each product type that does not reduce the total number of orders for all the functional parts attached to the product within the limits of the number of products that can be produced by type. .
[0028]
DETAILED DESCRIPTION OF THE INVENTION
The invention described in each of the above claims can be suitably implemented in the following forms.
(Mode 1) “Period / part production line / part type / number of production plans” calculation means can calculate the part type even if the production plan number of the part type produced in another part production line is increased from the necessary production number. According to the condition that the production plan number of the product production line to which the product is supplied does not exceed the production possible number.
(Mode 2) “Order source / product type / number of orders” totaling means calculates the number of orders for each order source / product type for each period, and stores “part production line / part type / manufacturable number / priority” storage means Stores the number of parts that can be produced by part type for each period.
In "period / parts production line / part type / production plan number" calculation means,
(1) For parts of which the number of production plans has been reduced from the required number of production, the reduction is compensated to increase the number of production plans for other periods,
(2) For parts types that have increased the number of production plans over the required number of production, the number of production plans over multiple periods can be reduced by executing processing to compensate for the increase and reduce the number of production plans in other periods. Means for adjusting can be added.
[0029]
【Example】
First, the relationship among product types, functional components, and component types in an embodiment to which the present invention is applied will be described with reference to FIG.
Box (1) of (I) corresponds to the product (automobile). In box (1), the upper model shows the vehicle type and the lower model shows the specification. Here, the number of specifications included in one vehicle type is i. For example, as shown in (II), the number of specifications included in the vehicle type α is i = 3, and specifications of α1, α2, and α3 exist. The number of specifications included in the vehicle type β is i = 2, and specifications of β1 and β2 exist. In this embodiment, the specification corresponds to “product type”.
Boxes (2) to (4) in (I) correspond to parts (units). The units of these boxes (2) to (4) are always attached to the automobile. In the box (2), the unit of the function E (engine) is shown in the upper part, and the type is shown in the lower part. For example, as shown in (II), the number of types of function E units used for the vehicle type α is j = 3, and types E1, E2, and E3 are used. The number of types of function E units used for the vehicle type β is j = 2, and types of E3 and E4 are used. In the box (3), the unit of the function M (transmission) is shown in the upper part, and the type is shown in the lower part. For example, as shown in (II), the number of types of units of the function M used for the vehicle type α is k = 2, and the types of M1 and M2 are used. The number of types of function M units used for the vehicle type β is k = 2, and types M3 and M4 are used. In the box (4), the unit of the function P (drive device) is shown in the upper stage, and the type is shown in the lower stage. For example, as shown in (II), the number of types of function P units used for the vehicle type α is l = 2, and the types of P1 and P2 are used. The number of types of function P units used for the vehicle type β is 1 = 1, and the type of P2 is used.
The specification of the automobile (corresponding to “product type”) is determined from the combination of the types of units of each function attached to the automobile. For example, as shown in (II), a combination of E1, M1, and P1 is attached to a vehicle of specification α1 of vehicle type α, and a combination of E2, M2, and P2 is attached to a vehicle of specification α2, and a vehicle of specification α3. A combination of E3, M2 and P2 is attached. In addition, a combination of E3, M3, and P2 is attached to an automobile of specification β1 of the vehicle type β, and a combination of E4, M4, and P2 is attached to an automobile of specification β2. There are also unit types that can be commonly attached to vehicles of different vehicle types, such as E3 attached to specification α3 and specification β1, and P2 attached to specification α2, specification α3, specification β1, and specification β2.
In box (5), the number of vehicles by month is shown in the upper row, and the number of monthly specifications is shown in the lower row. In this embodiment, the month corresponds to the “planning period”.
As will be described later, the order information from the sales department and the production plan number reply information to the sales department are reported in association with boxes (1) to (5).
[0030]
Next, with reference to FIG. 2, a system configuration of an apparatus for planning a production number plan for each product type (hereinafter simply referred to as a production number plan planning apparatus) will be described.
The production number planning device 6 is a computer for inputting, storing, calculating, outputting a calculation result, and operating a peripheral device based on the calculation result, and a description of pure hardware is omitted. The production number planning device 6 may be composed of a single computer, and if necessary, each function of input, storage, calculation and output is distributed to a plurality of computers, and the computers are connected via a network. In addition, a plurality of computers may be configured to operate as one production quantity planning apparatus 6.
In the present embodiment, the production number planning device 6 compiles monthly (by planning period) production number plans for a plurality of months at once (for example, a production number plan for N month and a production number plan for N + 1 month) N + February production plan is calculated at once). These multiple months (for example, N month to N + February) are hereinafter referred to as “quarterly”.
The production number planning device 6 is installed in a production department that accepts orders from the sales department and drafts a production number plan for automobiles. The production number planning device 6 is connected via a computer network so as to be communicable with the general computers 2 and 4 of the sales department on the side of the automobile.
The overseas sales department supervising computer 2 is connected so as to be able to communicate with each overseas sales agent, and the domestic sales department supervising computer 4 is connected so as to be able to communicate with each domestic dealer. For example, if the first month of the quarter (for example, N month) is one month later, each overseas sales agent will be within the predetermined acceptance period of the sales department (for example, between N and February before N month). Or, from each domestic sales store, order information that describes which specification of which model of which model and how many to order in the quarter (vehicle type / specification / number of orders) is sent monthly. The sales department supervising computers 2 and 4 collect these order information and assess whether the production request based on the order information deviates from the sales plan set in the quarter. The order information determined according to the assessment of the sales department supervising computers 2 and 4 is sent to the production number planning device 6 within a predetermined acceptance period of the production department (for example, during N-1 month before N month). It is done.
The order information sent to the production quantity planning device 6 is received by the order information receiving / aggregating means 8 and aggregated, and stored in the order information storage means 32.
FIG. 3 (1) shows an example of the data structure of the order information for the vehicle type α in the four quarters (N month to N + February) from country a, country b and country c. In the present embodiment, it is assumed that the production department is located in country a, country a is domestic, and country b and country c are overseas. For example, from country a, the specification α1 is ordered 350 units in N month, 500 units in N + 1 month, 350 units in N + February, and the specification α2 is 150 units in N month, 500 units in N + 1 month, in N + February. It is shown that 150 units were ordered, and the specification α3 was ordered 150 units in N month, 150 units in N + 1 month, and 150 units in N + February. Similarly, the specification of the vehicle type α ordered from each order country and the information on the number of orders from N month to N + February are shown. Also, (2) shows the total number of orders ordered by specification by month.
Here, only the order information for the vehicle type α is shown, but the vehicle type β and the vehicle type γ are also ordered in the same manner. In the following, for the sake of simplicity, description will be given only for the vehicle type α.
[0031]
The production number planning apparatus 6 includes vehicle line information storage means 34. The vehicle line information storage means 34 stores a vehicle line that produces an automobile, a country in which the vehicle line exists, a vehicle type that can be produced, a monthly production capacity, and a priority order of the order country in association with each other.
FIG. 4 shows a data configuration example of vehicle line information for all automobile production factories owned by the production company. Since one vehicle line exists in one country, the vehicle line and the vehicle production country are shown in association with each other. For example, the number of cars that can be produced in the vehicle line La (country a) is 800 in N, N + 1, and N + February, and the order of priority in the order country is country a, country 2 is country b, and country 3 Country c, the number of vehicles that can be produced in the vehicle line Lb (country b) is 1,200 in N, N + 1, and N + February. The third place is country c. On the other hand, the number of vehicles α that can be produced in the vehicle line Lc (country c) is 1000 in N, N + 1, and N + February, while it is 1200 in N + February. This is because the number of products that can be produced is scheduled to increase due to changes in production facilities, the number of workers, work hours, and the like.
[0032]
The production number planning device 6 includes a vehicle line / vehicle type / specification / required production quantity calculation means 10. The vehicle line / vehicle type / specification / production required number calculating means 10 is based on the information in the order information storage means 32 and the information in the vehicle line information storage means 34, and the vehicle types, specifications and production to be produced in each vehicle line on a monthly basis. Calculate the required number.
When the vehicle line / vehicle type / specification / required production quantity calculation means 10 determines that the total production requirement quantity of all vehicle types by month exceeds the total production capacity quantity of all vehicle lines owned by the production company by this calculation process. Determines whether or not the vehicle line can increase the excess. When it is determined that the production cannot be increased, the response information transmitting means 18 replies to the sales department supervising computer 2 or 4 that is the transmission source of the order information of the excess vehicle type. The sales department supervising computer 2 or 4 refers to the answer and adjusts the number of orders so that the number is less than the number of vehicles that can be produced on the vehicle line, and then sends the order information to the production number planning device 6 again. Based on the order information stored in the order information storage means 32 after being retransmitted, the vehicle line / vehicle type / specification / production required number calculation means 10 revisits the vehicle type and specifications to be produced in each vehicle line on a monthly basis. Calculate the required number of production.
[0033]
The calculation result of the vehicle line / vehicle type / specification / required production quantity calculating means 10 is stored in the vehicle line / vehicle type / specification / required production quantity information storage means 36.
FIG. 5 shows the calculation results for the vehicle type α stored in the vehicle line / vehicle type / specification / required production quantity information storage means 36. (1) shows the number of production required for each vehicle line. For example, in the vehicle line La (country a), the specification α1 of the vehicle type α is 350 units in N month, 500 units in N + 1 month, and 350 units in N + February. It is necessary to produce 150 units of specification α2 in N month, 150 units in N + 1 month, 150 units in N + February, and 150 units in specification N3, 150 units in N + 1 month, 150 units in N + February. It is shown that it is necessary to produce a stand. In the same manner, vehicle type / specifications that need to be produced in each vehicle line and information on the number of vehicles required for production from N month to N + Feb are shown. Also, (2) shows the total required number of productions compiled by specification by month. Furthermore, in (3), the required number of production summarized by specification and by vehicle line by month is shown.
[0034]
The production number planning device 6 includes a vehicle type / specification / unit type combination information storage means 38. The vehicle type / specification / unit type combination information storage means 38 stores information on the combination of types of units attached to the specifications of each vehicle type as shown in FIG.
[0035]
The production number planning apparatus 6 includes unit line information storage means 40. The unit line information storage means 40 stores the unit line that produces the unit, the country in which the unit line exists, the unit function that can be produced, its type, the number of products that can be produced by month, and the priority of the vehicle line in association with each other. Yes.
FIG. 6 shows a data configuration example of unit line information for all unit production factories owned by the production company. Since one unit line exists in one country, the unit line is associated with the unit production country. For example, unit line LA (country A), unit line LB (country B), unit line LC (country C) are lines for producing units of function E. ~ N + February 850 can be produced, and the priority order of the vehicle line is La for the first place, Lb for the second place, and Lc for the third place. The unit line LB can produce 1200 types E2 from N-February to N + February, and the priority order of the vehicle line is Lb for the first place, La for the second place, and Lc for the third place. The unit line LC can produce 1200 types E3 from N-February to N + February, and the priority order of the vehicle line is La for the first place, Lb for the second place, and Lc for the third place. Here, the priority order of the product line is determined based on the lead time from the component line to the product line. Similarly, for each unit line, the unit functions and types that can be produced, the number of units that can be produced, and the priority order of the vehicle lines are shown.
[0036]
The production number planning apparatus 6 includes a lead time information storage unit 42. The lead time information storage means 42 stores the lead time from each unit line (each unit production country) to each vehicle line (each vehicle production country). The lead time is (1) the number of days required for the unit to be shipped from the unit production factory after the production instruction is entered into the unit line, and (2) from the time the unit is shipped from the unit production factory to the port. (3) The number of days required for a unit to arrive at the vehicle production country after it is loaded in the unit production country, and (4) the number of days required for the unit to be carried into the vehicle production factory from the port. (5) It is calculated by adding up all the required days from the time the unit is carried into the vehicle production factory until it is transported to the vehicle line.
FIG. 7 shows a data configuration example of the lead time information. For example, the lead time from the unit line LA (country A) to the vehicle line La (country a) is 0 days. This is because the unit production country A and the vehicle production country a are the same country, and the distance from the unit line LA to the vehicle line La is short. The lead time from the unit line LA (country A) to the vehicle line Lb (country b) is 15 days. Similarly, the lead time from each unit line (each unit production country) to each vehicle line (each vehicle production country) is shown.
[0037]
The production number planning device 6 includes shipping / shipping frequency information storage means 44, line working day information storage means 46, and vehicle line / unit function / type / safety stock quantity information storage means 48. The shipping / shipping frequency information storage means 44 stores the day of the week when the unit is shipped from the unit production factory and the day of the week when the unit is loaded in the unit producing country. The line working day information storage means 46 stores the working day of each vehicle line and each unit line. The vehicle line / unit function / type / safety stock quantity information storage means 48 stores the safety stock quantity by unit function / type necessary for the vehicle type / specifications produced by the vehicle line for each vehicle line. The safety stock quantity is the number of stocked units that are not missing even if the number of units used in the vehicle line per day is subtracted or due to delays in delivery of the units. For example, even if 20 units used on the vehicle line are subtracted per day, if the safety stock quantity is 100, 80 units remain at the end of the day's operation, resulting in a delivery delay of up to 4 days. Can be dealt with.
[0038]
The production number planning device 6 includes a unit line / unit function / type / production planned number calculation means 12. The unit line / unit function / type / production plan number calculation means 12 first (1) information of the vehicle line / vehicle type / specification / required production quantity information storage means 36 and the vehicle type / specification / unit type combination information storage means 38. Based on the information, the information in the unit line information storage means 40, the information in the lead time information storage means 42, the information in the shipping / shipping frequency information storage means 44, the information in the line working day information storage means 46, the vehicle With reference to the information in the line / unit function / type / safety stock quantity information storage means 48, the required production quantity sufficient to satisfy the required production quantity for each unit function / type, for each vehicle line, for each vehicle type / specification is calculated. If the unit line / unit function / type / production required quantity calculated in this way exceeds the unit line / unit function / type / production possible quantity stored in the unit line information storage means 40, (2) After the vehicle line / vehicle type / specification / production planned number subtraction adjusting means 14 to be described performs production reduction adjustment, back line adjustment is performed to calculate unit line / unit function / type / production planned number. In addition, (3) the number of planned productions is also increased or decreased in conjunction with other functions / types of units that are attached to the vehicle having the same specifications as the unit type that has been adjusted. The calculation processes (1) to (3) will be described in detail later.
[0039]
The production number planning device 6 can also include a unit line / unit function / type / stock quantity information storage means 50. The unit line / unit function / type / stock quantity information storage means 50 stores the stock quantity by unit function / type by day (by period) for each unit line. In the unit line, in order to avoid a situation where the unit cannot be shipped due to a sudden accident, a predetermined number of units are preliminarily produced rather than the actual production plan number, and this is accumulated daily and is in stock. If the inventory units are excessively accumulated in excess of the safety stock quantity, the excess inventory units may be shipped with priority. In addition, the units produced in the unit line are not shipped immediately but are stocked waiting for shipment at the unit production factory. The unit line / unit function / type / stock quantity information storage means 50 stores all of these stock units, and the unit line / unit function / type / production plan quantity calculation means 12 considers excess stock units. Thus, the net required production quantity can be calculated.
The unit line / unit function / type / inventory quantity information storage means 50 is not an essential component of the production quantity planning apparatus 6.
[0040]
The production number planning device 6 includes vehicle line / vehicle type / specification / production planned number subtraction adjustment means 14. The vehicle line / model / specification / production plan number subtraction adjustment means 14 is necessary for the unit line / unit function / type / production plan quantity calculation means 12 and the required number of production by unit function / type exceeds the production capacity of the unit line. When doing so, first (1) reduce the production of the unit type produced by the unit line. Then, (2) among the vehicle lines that produce the specifications affected by the production reduction adjustment of the unit type, adjustment is made as to how much production is reduced in which vehicle line. This adjustment process will be described in detail later.
[0041]
At the time of production reduction adjustment, the information in the previous vehicle line / vehicle type / specification / production plan number information storage means 52 can be referred to. The last vehicle line / vehicle type / specification / production plan number information storage means 52 receives the quarterly period (for example, during the N-March two months before the N-January period) during the previous order predetermined reception period (e.g. Information on the number of production plans by type of vehicle according to the vehicle line according to the production plan designed based on the order information of (N-November to N + 1).
[0042]
The result of the production reduction adjustment process is returned to the unit line / unit function / type / production planned number calculation means 12, and the above-described back stitch adjustment and interlock adjustment are performed based on this.
The calculation results obtained by the unit line / unit function / type / production plan number calculation means 12 performing the backside adjustment and the interlock adjustment are stored in the unit line / unit function / type / production plan number information storage means 54.
FIG. 9B illustrates unit line / unit function / type / production plan number information for each unit by month. For example, in unit line LA (country A), it is calculated that unit E1 is planned to be produced at 225 units in N-1 month, 850 units in N month, 850 units in N + 1 month, and 525 units in N + February. .
[0043]
The production number planning device 6 includes a production plan number calculation means 16 by vehicle type / specification / unit function / type. Based on the information in the unit line / unit function / type production plan number information storage means 54, the vehicle type / specification / unit function / type production plan number calculation means 16, the information of the lead time information storage means 42, and the shipment / distribution By referring to the information in the ship frequency information storage means 44 and the information in the line working day information storage means 46, the information in the vehicle line information storage means 34 and the information in the vehicle type / specification / unit type combination information storage means 38 are used. Then, for each month, the planned production quantity by vehicle type / specification and the planned production quantity by unit function / type are calculated. This calculation process will be described in detail later.
[0044]
The calculation result of the production plan number calculation means 16 by vehicle type / specification / unit function / type is stored in the production plan number information storage means 56 by vehicle type / specification / unit function / type, and is sent from the response information transmission means 18 to the sales department. It is transmitted to the central computers 2 and 4.
FIG. 10 exemplifies information on the number of production plans by vehicle type / specification. (1) shows the number of production plans collected by vehicle line by month. For example, in the vehicle line La (country a), the specification α1 of the vehicle type α is shown. Is planned to produce 350 units in N month, 387 units in N + 1 month, 350 units in N + February, and specifications α2 will be produced in 150 units in N month, 206 units in N + 1 month, and 206 units in N + February. It is calculated that the specification α3 is planned to be produced in 150 units in N month, 206 units in N + 1 month, and 150 units in N + February. In the same manner, vehicle type / specifications planned for production in each vehicle line and information on the number of production plans from N month to N + Feb are shown. (2) shows the total number of production plans compiled by specification by month. (3) shows the number of production plans compiled by month and by vehicle line by specification.
Further, FIG. 9B illustrates unit function / type-specific production plan number information, which are grouped by month and by unit line.
[0045]
Next, with reference to the flowcharts of FIG. 11 to FIG. 13, a description will be given of a process in which the production number plan planning device 6 drafts a production number plan by vehicle type / specification by month (by planning period). In the present embodiment, a case will be described in which a monthly production number plan for the quarter of N month to N + February is made based on the order information transmitted from the sales department during N-1 month.
[0046]
First, with reference to the flowchart of FIG. 11, a procedure for calculating the required number of vehicles to be produced and how many types / specifications need to be produced in which vehicle line will be described.
First, the order information receiving / aggregating means 8 receives the order information determined through the assessment by the sales department supervising computers 2 and 4, and aggregates the number of orders by month, by vehicle type, and by specification (step S2). The count result is stored in the order information storage unit 32. FIG. 3 exemplifies a total result stored in the order information storage unit 32.
[0047]
Next, based on the information in the order information storage means 32 and the information in the vehicle line information storage means 34, the vehicle line / vehicle type / specification / production required number calculation means 10 determines which vehicle type on the vehicle line for each month. Calculate how many specifications need to be produced. For example, in the order information of FIG. 3 (1), the total number of vehicles of the model α (specifications α1, α2, α3) from country a is 650 in N month, 1150 in N + 1 month, and 650 in N + February. On the other hand, according to the vehicle line information shown in FIG. 4, only 800 cars can be produced in N month, N + 1 month, and N + February in vehicle line La (a country). Therefore, in FIG. 5 (1), the necessary number of productions of the specification α2 for N + 1 month of the vehicle line La (country a) is subtracted to 350 units to 150 units, and the vehicle type α is calculated to produce a total of 800 units in N + 1 month. ing. In addition, it is calculated that 350 units of the specification α2 that cannot be produced in the vehicle line La in N + 1 month are added to the vehicle line Lb (country b) to 500 units, and the vehicle type α is produced in total of 1150 units in N + 1 month. Both the vehicle lines La and Lb are within the range of the number that can be produced. In this way, which vehicle line is to be used instead of the amount that cannot be produced in a certain vehicle line is determined based on the priority order of the order country set in the vehicle line.
[0048]
In step S6 of FIG. 11, the vehicle line / vehicle type / specification / required number of production calculation means 10 performs the above calculation processing to determine that the total required number of production for each vehicle type is the vehicle type of all vehicle lines held by the production company. If it is determined that the total production capacity is exceeded, it is determined whether the vehicle line can increase the excess. For example, in the vehicle line / vehicle type / specification / production required number information in FIG. 5 (2), the total production required number of the vehicle type α (specifications α1, α2, α3) is 2650 in N month, 2600 in N + 1 month, N + February 2350 units. In the vehicle line information of FIG. 4, the total production possible number of the vehicle type α is 3000 in N month, 3000 in N + 1 month, and 3200 in N + February. The total production required for each vehicle type does not exceed the total production capacity for each vehicle line of the production company. Therefore, it determines with NO and transfers to step S10.
On the other hand, when it determines with YES, it transfers to step S8 and determines whether the vehicle line which can produce the specification in which the required number of production exceeded has increased the excess. When it is determined that the production can be increased (in the case of YES), the process proceeds to step S10. On the other hand, when it is determined that the production cannot be increased (in the case of NO), the process proceeds to step S9, and the response information transmitting means 18 transfers to the sales department supervising computer 2 or 4 that is the transmission source of the excess vehicle type and specification order information. Reply to that effect. The sales department supervising computer 2 or 4 refers to the answer and adjusts the number of orders so that the number is less than the number of vehicles that can be produced on the vehicle line, and then sends the order information to the production number planning device 6 again.
Based on the order information stored in the order information storage means 32 after being retransmitted, the vehicle line / vehicle type / specification / production required number calculation means 10 revisits the vehicle type and specifications to be produced in each vehicle line on a monthly basis. Calculate the required number of production.
[0049]
In step S10, the monthly vehicle line / vehicle type / specification / required number of production calculated in the processes so far are distributed by day. In this embodiment, the required number of each month is allocated on the 25th working day in the month. For example, in the vehicle line / vehicle type / specification / required production quantity information in FIG. 5 (1), since the specification α1 produced in the vehicle line La in N month is 350 units, the daily necessary production number is 14 units. Become.
[0050]
As described above, after calculating the number of which specifications of which vehicle type in which vehicle line and how much it is necessary to produce, the unit line / unit function / type / production planned number calculating means 12 calculates the vehicle line / vehicle type / Based on the information in the specification / production required number information storage means 36, the information in the vehicle type / specification / unit type combination information storage means 38, and the information in the unit line information storage means 40, the units to be produced in each unit line on a daily basis Calculate function / type and number. At this time, the information in the lead time information storage means 42, the information in the shipping / shipping frequency information storage means 44, the information in the line working day information storage means 46, and the vehicle line / unit function / type / safety stock quantity information storage. The information of the means 48 is referred to.
[0051]
The procedure of unit line / unit function / type / production plan number calculation processing will be described with reference to the flowcharts of FIGS.
First, in step S12 of FIG. 12, the vehicle line i and the unit line j to be processed first are selected. The unit line j can be arbitrarily selected. Here, the unit line LA is selected. The vehicle line i is selected in order from the vehicle line that is ranked first in the priority order of the product lines stored in the unit line storage means information storage means 40. Here, the vehicle line La is selected from FIG.
[0052]
In the subsequent step S14, the unit line / unit function / type / production planned number calculation means 12 includes information on the vehicle line / vehicle type / specification / required production quantity information storage means 36 and vehicle type / specification / unit type combination information storage means 38. The number of daily unit functions / types necessary for the vehicle type / specifications produced in the vehicle line i is calculated based on the above information. In the above example, since it is necessary to produce 14 specifications α1 of the vehicle type α on the vehicle line La in N month / day, the necessary production number required for the specification α1 among the units E1 produced on the unit line LA is Calculate 14 / day.
[0053]
In step S16, the unit line / unit function / type / production plan number calculation means 12 performs the information in the lead time information storage means 42, the information in the shipping / shipping frequency information storage means 44, and the line operation date information storage means 46. With reference to the above information, a timeline from when a unit production instruction is input to the unit line j to when it is conveyed to the vehicle line i is set.
A timeline setting method will be described with reference to FIG. For convenience of explanation, an example in which the lead time of the unit line LA (country A) to the vehicle line Lb (country b) is 15 days will be taken. This lead time depends on (1) the number of days required for the unit to be shipped after the unit production instruction is entered into the unit line LA (2 days), and (2) the time from when the unit is shipped to the port. Required time (2 days), (3) Required time (7 days) from unit loading in unit production country a to arrival in vehicle production country b, (4) Unit from the port to vehicle production factory The total number of days required (2 days) and (5) the number of days required for the unit to be transported to the vehicle line Lb (2 days). It is a combination. Thus, for example, if the production instruction date is January 1st, the shipping date is January 3rd, the shipping date is January 5th, the port arrival date is January 12th, and the vehicle production factory delivery date is January 14th. Each timeline can be set as the date of transportation on the day of the month and the vehicle line.
Here, since the lead time from the time when the production instruction is input to the unit line LA first selected in step S12 in FIG. 12 until it is transferred to the vehicle line La is 0 days, the time lines are all on the same day. Set to
[0054]
In step S18 of FIG. 12, the unit line / unit function / type / production planned number calculation means 12 receives the unit function / type in the vehicle line i from the vehicle line / unit function / type / safety stock quantity information storage means 48. Get another safety stock quantity. The specification α1 is produced in the vehicle line La first selected in step S12, and the unit E1 is produced in the unit line LA first selected in step S12. Therefore, the safety stock quantity 100 for the unit E1 is acquired.
[0055]
In step S20, the unit line / unit function / type production plan number calculation means 12 calculates the necessary number of units of unit function / type for each unit line j. First, in order to prevent the unit of the vehicle line i from falling below the safety stock quantity at the start of operation on the day, the timeline set in step S16 is traced back to determine which unit function / Calculate how many types need to be produced. For example, in step S14, it was calculated that 14 units E1 were used per day in the vehicle line La in N month. Even if the number is reduced by 14 per day, the time line is traced back so that the safety stock quantity does not fall below 100 on the vehicle line La side, and the unit E1 is on the day of the month on the unit line LA. Calculate how much you need to produce.
Here, if the unit line / unit function / type / inventory quantity information storage means 50 is provided, the unit inventory quantity on the unit line side is acquired, and the net required production quantity is calculated by subtracting the inventory quantity. May be.
FIG. 8 (1) shows an example in which the necessary number of daily unit functions / types produced by the unit line LA for the vehicle line La are summarized by month. Here, the net required production quantity is calculated on the assumption that the excess inventory quantity of units on the unit line LA side is zero. Since the lead time from the unit line LA to the vehicle line La is 0 day, 14 units / day (350 units / month) for the vehicle line La in N month and 20 units / day in N + 1 month ( It is calculated that it is necessary to produce 14 pieces / day (350 pieces / month) in N + February.
[0056]
In step S22, the unit line / unit function / type / production plan number calculation means 12 determines whether there is a next vehicle line that uses a unit produced by the unit line j. Since the vehicle lines Lb and Lc that use the unit E1 produced in the first selected unit line LA remain, it is determined YES, and the vehicle line Lb with the second highest priority is selected in step S24, and step S14. Returning to step S22, the series of processing up to step S22 is repeated. After repeating the series of processes for the vehicle line Lb, the vehicle line Lc with the third highest priority is selected in step S24, the process returns to step S14, and the series of processes up to step S22 is repeated.
FIG. 8 (1) shows an example in which the required number of daily unit functions / types produced by the unit line LA for the vehicle lines Lb and Lc, calculated by a series of processes, is summarized by month. Yes. Since the lead time from the unit line LA to the vehicle line Lb is 15 days, the number of unit E1 for the vehicle line Lb is 6 / day (75 / second month) in the second half of N-N 6 pieces / day (150 pieces / month), 6 pieces / day in the first half of N + 1 month (75 pieces / first half month), 14 pieces in the second half of N + 1 month (175 pieces / second half month), 14 pieces in the first half of N + February / Day (175 pieces / first half of the month) needs to be produced. Since the lead time to the vehicle line Lc is 30 days, the unit E1 for the vehicle line Lb is 6 units / day (150 units / month) in N-1 month and 14 units / day (350 units) in N month. / Month), it is calculated that it is necessary to produce 14 pieces / day (350 pieces / month) in N + 1 month.
[0057]
As described above, when a series of processing has been performed for all the vehicle lines that use the units produced in the unit line j, the process proceeds to step S26, and the unit line / unit function / type / production planned number calculation means 12 is entered. However, the required number of unit lines LA is accumulated by day.
FIG. 8 (2) shows an example in which the required number of unit lines LA is integrated daily. In the second half of N-Jan, it is necessary to produce 6 units / day for the vehicle line Lb, and because it is necessary to produce 6 units / day for the vehicle line Lc throughout N-Jan, It is estimated that it is necessary to produce 6 pieces / day in the first half of N-Jan and 12 pieces / day in the second half (the total for N-Jan is calculated to be 225). Similarly, the necessary number of production from N month to N + February is integrated by day.
[0058]
In the subsequent step S28 in FIG. 12, the unit line / unit function / type / production plan number calculation means 12 determines whether there is a next unit line. Since the unit lines LB, LC, LD, LE, LF, and LG still remain, it is determined as YES, the next unit line LB is selected in step S30, and the vehicle line Lb with the highest priority is selected. Then, returning to step S14, a series of processing up to step S28 is repeated.
[0059]
When the series of processing from step S14 to step S26 is repeated for the unit lines LB and LC, as shown in FIG. 8 (2), the necessary number of production for the unit lines LB and LC is integrated on a daily basis.
When the series of processing from step S14 to step S26 is repeated for the remaining unit lines LD, LE, LF, LG, NO is determined in step S28, and the process proceeds to step S32 in FIG.
[0060]
In step S32, as a result of the unit line / unit function / type / production plan number calculation means 12 performing the integration process in step S26, it is determined whether the daily required number of production does not exceed the line load of each unit line ( It is determined whether or not the production capacity of each unit line is exceeded. If it is determined that all unit lines do not exceed the line load, the calculation results so far are stored in the unit line / unit function / type / production plan number information storage means 54, and the process proceeds to step S46.
On the other hand, for example, in FIG. 8 (2), the necessary production number (1100) of the unit E1 in the unit line LA exceeds the production possible number (850 indicated by a dotted line in the horizontal direction) on the whole day of N month + 1 by 250. . In such a case, NO is determined in step S32 of FIG. 13 and the process proceeds to step S34.
[0061]
In step S34, the unit line / unit function / type / production plan number calculating means 12 determines whether or not the unit line determined to exceed the line load in step S32 can increase the excess. If the production can be increased (YES in determination), the calculation results so far are stored in the unit line / unit function / type / production planned number information storage means 54, and the process proceeds to step S46. On the other hand, if the production cannot be increased (NO in determination), the process proceeds to step S36.
[0062]
In step S36, the vehicle line / vehicle type / specification / production planned number reduction production adjustment means 14 adjusts the production reduction of the production line number of the vehicle line that uses the unit produced by the unit line determined to be unable to increase production in step S34. For example, in FIG. 8 (2), the production planned number of the vehicle lines La, Lb, and Lc using the unit E1 of each day of N + 1 month that has exceeded the line load in the unit line LA is the excess of the unit E1. Adjust to reduce production.
In this case, first, (1) when the excess of the unit E1 on each day of N + 1 month that exceeded the line load in the unit line LA is used in which vehicle line (vehicle line producing the specification α1) Recognize that there is. By following the timeline set in step S16, as shown in FIG. 9 (1), this is the amount used for each day of N + 1 month in the vehicle line La, and the second half of N + 1 month in the vehicle line Lb. To the first half of N + February and can be recognized as being used on each day of N + February on the vehicle line Lc.
After recognizing the vehicle line that uses the excess unit and the time of use, next, (2) determine which vehicle line should be allocated to reduce the production by using what proportion of the unit E1 . For example, the following two methods can be considered as a method for determining the allocation ratio.
One method is as follows: (a) For the vehicle lines La, Lb, and Lc using the unit E1, the previous production line number stored in the previous vehicle line / vehicle type / specification / production quantity unit information storage means 52 The difference ratio of the required number of production this time is calculated for each vehicle line. Then, the ratio of the difference ratio of each vehicle line in the total difference ratio of all the vehicle lines is obtained, and this is used as the allocation ratio. For example, if the number of planned productions for each day of the last N + 1 month of the vehicle line La is 25 / day and the current required number of production is 20 / day, the difference ratio is (25-20) / 25 = 0. .2. If the production planned number for each day from the last half of N + 1 month to the first half of N + February of the vehicle line Lb is 15 pieces / day, and the required number of production this time is 10 pieces / day, the difference ratio is (15 −10) /15=0.33. If the production planned number for each day of the previous N + February of the vehicle line Lc is 21 pieces / day and the required number of production this time is 14 pieces / day, the difference ratio is (21-14) / 14 = 0. .5. The ratio of the difference ratio of each vehicle line in the total of these difference ratios is obtained, and this is used as the allocation ratio. The ratio of the vehicle line La difference ratio is 0.2 / (0.2 + 0.33 + 0.5) = 0.19, and the ratio of the vehicle line Lb difference ratio is 0.33 / (0.2 + 0.33 + 0.5). = 0.32, and the ratio of the vehicle line Lc is calculated as 0.5 / (0.2 + 0.33 + 0.5) = 0.49, which is used as the allocation ratio.
Another method is (b) determining the ratio of the number of units used in each vehicle line to the required number of units of production, and using this as the allocation ratio. For example, if the required number of units E1 on each day of N + 1 month of the unit line LA is 44 / day and the number of N + 1 months used on the vehicle line La out of 44 is 20 / day, the vehicle The ratio of the number used in the line La is 20/44 = 0.45. If the number of used days on the vehicle line Lb from the second half of N + 1 month to the first half of N + February is 10 / day, the ratio of the number used on the vehicle line Lb is 10/44 = 0.23. If the number used in N + February in the vehicle line Lc is 14 / day, the ratio of the number used in the vehicle line Lc is 14/44 = 0.32. The ratio of these numbers used is the allocation ratio.
After deciding which vehicle line to allocate and reduce production in this way, (3) multiplying the allocation ratio of each vehicle line by the excess of the unit 250 to reduce production in each vehicle line Calculate minutes. Thus, for example, it is determined how much the specification α1 is to be reduced in the vehicle lines La, Lb, and Lc that use the unit E1. For example, when the allocation ratio of (b) is adopted, 0.45 × 250≈113 units in the vehicle line La, 0.23 × 250≈58 units in the vehicle line Lb, and 0.32 × 250 = It is decided to reduce production of 80 specifications α1. That is, 500-113 = 387 units in N + 1 month in the vehicle line La, 250-58 = 192 units in the second half of N + 1 month to the first half of N + February in the vehicle line Lb, 350-80 = 270 units in N + February in the vehicle line Lc. Adjusted to produce.
The result of the production reduction adjustment process is returned to the unit line / unit function / type / production planned number calculation means 12. As a result of the return, as shown in FIG. 9 (2), the production plan number of the unit E1 in the unit line LA of N + 1 month is calculated. It is calculated that 387 for the vehicle line La, 75 + 118 = 193 for the vehicle line Lb, and 270 for the vehicle line Lc, a total of 850, which is the same as the 850 that can be produced.
[0063]
In the subsequent step S38 of FIG. 13, the unit line / unit function / type / production plan number calculation means 12 determines whether the back of the unit type can be adjusted. Backward adjustment means increasing the production of other unit types that have a margin to the number of units that can be produced from the same function unit, in order to avoid reducing the total number of vehicles required for production. To make adjustments. When the back adjustment is performed, the number of production plans for each unit type is changed from the number of orders, so the number of production plans for each specification is also changed from the number of orders. However, the total planned production volume of the model can maintain the total number of orders of the model. If the total number of orders is maintained, loss of sales opportunities for the entire vehicle model can be minimized.
For example, in FIG. 8 (2), the excess of the unit E1 on each day of N + 1 month that exceeded the line load in the unit line LA is increased to the unit E2 in the unit line LB, or the unit E3 in the unit line LC. Adjust to increase production. In this case, first, (1) the day when the excess of the unit E1 on each day of N + 1 month that exceeded the line load on the unit line LA is used on each vehicle line is recognized. As shown in FIG. 9 (1), the vehicle line La recognizes each day of N + 1 month, the vehicle line Lb recognizes each day from the second half of N + 1 to the first half of N + February, and the vehicle line Lc recognizes each day of N + February. .
If the date of use in the vehicle line can be recognized in this way, then (2) the production planned number of specifications α2 produced using the unit E2 on the date of use and the unit E3 are produced. In proportion to the planned production volume of specification α3, the excess of unit E1 is allocated to unit line LB that produces unit E2 and unit line LC that produces unit E3. And For example, from FIG. 9 (1), the specification α2 produced using the unit E2 on the above-mentioned use date is the planned production number 150 for N + 1 month in the vehicle line La and the second half of N + 1 month in the vehicle line Lb. To the first half of N + February and the planned production number 350 of N + February in the vehicle line Lc is 510. The specification α3 produced using the unit E3 includes the production planned number 150 of N + 1 month in the vehicle line La, the production planned number 325 of the vehicle line Lb from the second half of N + 1 January to the first half of N + February, The total production number 350 of N + February in the line Lc is added to 510. Therefore, the ratio of the production plan number of the specification α2 and the specification α3 is 1: 1, and the excess of the unit E1 is allocated to the unit line LB and the unit line LC at this ratio, and the increased production of the unit E2 is 125. Increase the production of unit E3 to 125.
Next, (3) it is recognized when the unit E2 used on the use day in the vehicle line is produced on the unit line LB and when the unit E3 is produced on the unit line LC. This can be recognized by tracing the timeline in reverse. For example, among the units E2 used for the specification α2 in FIG. 9 (1), the units used on each day of N + 1 month on the vehicle line La are units on the unit line LB from the second half of N month to the first half of N month. Recognize that it is produced every day. It is recognized that the vehicle line Lb used on each day from the second half of N + 1 January to the first half of N + February is produced on the unit line LB on each day from the second half of N + 1 January to the first half of N + February. It recognizes that what is used on each day of N + February on the vehicle line Lc is produced on each day of N + 1 in the unit line LB. Recognizing that unit E3 used for specification α3, which is used on each day of N + 1 month in vehicle line La, will be produced on the unit line LC every day from the second half of N month to the first half of N month To do. It is recognized that what is used on the vehicle line Lb on each day from the second half of N + 1 January to the first half of N + February is produced on each day from the second half of N + 1 January to the first half of N + February on the unit line LC. It recognizes that what is used on each day of N + February on the vehicle line Lc is produced on each day of N + 1 in the unit line LC.
When the production date of another type of unit can be recognized in this way, (4) when the production reduction is increased on that day on the other unit line, it is determined whether or not the line load of that unit line is exceeded. That is, as shown in FIG. 9 (2), when the production reduction is increased on the date recognized in the unit line LB, the production possible number of the unit line LB exceeds 1200 units / month (= 48 units / day). It is determined whether or not. In FIG. 9 (2), the portion of the unit line LB where the reduced production is increased in N month, N + 1 month and N + February is indicated by hatching. Even if the production is increased in this way, the production capacity of the unit line LB does not exceed 1200 pieces / month. Similarly, the portion of the unit line LC where the reduced production is increased in N month, N + 1 month and N + February is indicated by hatching. Even if the production is increased in this way, the production capacity of the unit line LC does not exceed 1200 pieces / month, so it is determined as No.
Finally, if it is determined that the line load of the unit line will not be exceeded in this determination, (5) When the production is increased on that day in the other unit line, the vehicle line that produces the vehicle using the unit for the increased production, It is determined whether the line load is exceeded on the corresponding day. In the above example, if unit E2 is increased in unit month LB in N month, N + 1 month, and N + February, vehicle line La that produces specification α2 using unit E2 for the increased production will exceed the line load in N + 1 month. It is determined whether the vehicle line Lb exceeds the line load from the second half of N + 1 month to the first half of N + February, and whether the vehicle line Lc exceeds the line load in N + February. When the unit line LC increases the production of the unit E3 in N, N + 1, and N + February, whether or not the vehicle line La that produces the specification α3 using the increased unit E3 exceeds the line load in N + 1, It is determined whether or not the vehicle line Lb exceeds the line load from the second half of N + 1 month to the first half of N + February, and whether the vehicle line Lc exceeds the line load in N + February. In this example, the specification α2 and the specification α3 that are adjusted to increase production are produced on the same vehicle line as the specification α1 that is adjusted to reduce production. Therefore, it is determined that the vehicle lines La, Lb, and Lc do not exceed the line load. The
If it is determined in (5) that the vehicle lines La, Lb, and Lc do not exceed the line load, YES is determined in step S38 in FIG. 13, and the above-described back eye adjustment is performed in step S40. On the other hand, if it is determined in (4) or (5) that the line load is exceeded, NO is determined in step S38, and the back stitch adjustment in step S40 and the following linked adjustment in steps S42 and S44 are performed. Is not performed, and the process proceeds to step S46.
[0064]
When the back stitch adjustment is performed in step S40 and the process proceeds to step S42, the unit line / unit function / type / production plan number calculation means 12 determines whether or not the related unit function can be linked and adjusted. Since each specification is determined by the combination of the type of unit E, the type of unit M, and the type of unit P, if the production plan number of the type of unit E is reduced or increased by adjusting the back stitch as described above, It is determined whether or not the number of production plans for the period corresponding to the type of unit M and unit P attached to the specification determined from the type can also be changed in conjunction.
In this case, first, (1) the type of the unit that has been reduced or the type of the unit function that needs to be adjusted in conjunction with the unit type that has been increased in the back adjustment, and the adjustment period are recognized. In the above example, the unit E1 produced on each day of N + 1 in the unit line LA has been reduced in production. Therefore, the unit M1 and the unit P1 attached to the specification α1 determined from the unit E1 are also reduced in a corresponding period. Recognize that you need to. For example, the specification α1 is produced on the vehicle line La using the unit E1 produced on the unit line LA on each day of N + 1 month, as shown in FIG. 9 (1), on each day of N + 1 month. is there. It is recognized that the unit M1 and the unit P1 for use on each day of N + 1 in the vehicle line La also need to be cut in conjunction with each other. In addition, the specification α2 is produced on the vehicle line Lb using the unit E1 produced on the unit line LA on each day of N + 1 January every day from the second half of N + 1 January to the first half of N + February. The unit M1 and the unit P1 for use on each day from the second half to the first half of N + February recognize that it is necessary to cut production in conjunction. Further, in the vehicle line Lc, the specification α3 is produced on the N + February day using the unit E1 produced on the unit line LA on the N + 1 february day for use on the N + February day. The unit M1 and the unit P1 recognize that it is necessary to cut production in conjunction with each other. On the other hand, the unit E2 produced in the unit line LB in N month, N + 1 month, and N + February is increased, so the unit M2 and the unit P2 that are attached to the specification α2 determined from the unit E2 are also linked in the corresponding period. Recognize the need to increase production. Unit E3 produced in N, N + 1, and N + February on unit line LC will be increased, so unit M2 and unit P2, which are attached to specification α3 determined from unit E3, will need to be linked together in the corresponding period. Recognize that there is.
After recognizing the unit type and adjustment period that need to be adjusted in this way, next, (2) the unit line that produces the unit type that needs to be adjusted and increased in production will exceed the line load during the adjustment period. It is determined whether or not. In the above example, it is determined whether or not the unit line that produces the unit M2 or the unit P2 that needs to be adjusted for increased production in conjunction with the unit E2 exceeds the line load during the adjustment period. It is determined whether or not the unit line that produces the unit M2 or the unit P2 that needs to be adjusted for increased production in conjunction with the unit E3 exceeds the line load during the adjustment period.
If it is determined in (2) that the unit line that produces unit M2 or unit P2 does not exceed the line load during the adjustment period, it is determined YES in step S42 of FIG. 13, and the above-described interlocking is performed in step S44. Adjustments are made. On the other hand, if it is determined in (2) that the line load is exceeded, NO is determined in step S42, the process returns to step S38, it is determined that the unit type back side adjustment cannot be performed, and the process proceeds to step S46.
[0065]
It should be noted that the number of unit functions / types to be produced in each unit line calculated so far before moving to step S46 is determined as the planned production number, regardless of whether YES or NO is determined in step S42. Once stored in the unit line / unit function / type / production plan number information storage means 54.
[0066]
In step S46, the vehicle type / specificity / unit function / type production plan number calculation means 16 calculates the production plan number of each vehicle type / specification and the production plan number of each unit function / type, by day / month.
First, based on the information in the unit line / unit function / type / production plan number information storage means 54, the information in the lead time information storage means 42, the information in the shipping / shipping frequency information storage means 44, and the line working day information By tracking the timeline based on the information in the storage means 46 and using the information in the vehicle line information storage means 34 and the information in the vehicle type / specification / unit type combination information storage means 38, which day of which month It is clear that it was planned to produce which vehicle type / specification on the vehicle line. If the number of production plans by vehicle type / specification by day is integrated, the production plan number by vehicle type / specification by month can also be calculated.
Also, from the information in the unit line / unit function / type / production planned number information storage means 54, it becomes clear how many unit functions / types are produced on which unit line on which day of which month. If the daily unit function / type production plan quantity is integrated, the monthly unit function / type production plan quantity can also be calculated.
[0067]
The daily / monthly vehicle type / specification production plan number and unit function / type production plan number calculated as described above are stored in the vehicle type / specification / unit function / type production plan number information storage means 56. The FIG. 10 illustrates information on the number of production plans by vehicle type / specification, and (1) shows the number of production plans compiled by vehicle line by month. The planned production number of the vehicle line La is the total required number of vehicles of the vehicle type La of the vehicle line La shown in FIG. 5 (1) (650 units in N month, 800 units in N + 1 month, 650 units with N + 2) In comparison, the total production plan for the monthly car model α (650 units in N month, 799 units in N + 1 month, 650 units in N + February) is almost the same. FIG. 10 (2) shows the total number of planned productions compiled by specification for each month. Furthermore, in (3), the production plan number summarized by vehicle line by specification by month is shown.
On the other hand, FIG. 9 (2) also shows an example in which the information on the unit function / type production plan number is summarized for each unit line by month.
[0068]
Based on the information on the number of production plans by vehicle type / specification / unit function / type, the number of production plans by vehicle type / specification and the number of production plans by unit function / type are allocated to each order country. 1) to (5) are created. The created answer information is sent from the answer information sending means 18 to the sales department supervising computers 2 and 4. If the production request from the sales department (vehicle type / specification / number of orders) cannot be met, the cause (for example, what type of which unit cannot be produced) and alternatives (other specifications) If it can be produced, it can be produced in other periods). That is, when the production cut-off adjustment at step S36 in FIG. 13 or the back adjustment at step S40 is performed, the vehicle type / specific production plan number and the unit function / type production plan number changed from the order number are transmitted. , You can ask the sales department to understand the shortfalls and changes.
The sales department supervising computers 2 and 4 send the reply information transmitted from the production number planning device 6 to each overseas sales agent or each domestic sales store. Each overseas sales agent or each domestic sales store adjusts the number of orders for each vehicle type / specification based on the response information and transmits the order information to the sales department supervising computers 2 and 4 again. The sales department supervising computers 2 and 4 return new order information to the production department. The production department formulates a formal production number plan based on the order information returned in this way.
[0069]
As described above, in this embodiment, when the product type is determined by the combination of the types of parts to be attached, the total production that can secure the total number of orders for each vehicle type even under the restriction of the number of products that can be produced for each part type. The number of plans can be calculated.
[0070]
Specific examples of the present invention have been described in detail above, but these are merely examples and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes of the specific examples illustrated above.
In the present embodiment, the automobile is a “product”, but the present invention is not limited to this.
In the present embodiment, the specification of the automobile corresponds to the “product type”, but is not limited to this. For example, it can be assumed that the vehicle type and grade correspond to the “product type”. Alternatively, the product item may correspond to a “product type”.
In the present embodiment, only one vehicle line exists in one vehicle producing country and only one unit line exists in one unit producing country. However, the present invention is not limited to this.
In the present embodiment, a plurality of specifications are produced in one vehicle line, but the present invention is not limited to this, and the present invention can also be applied to a vehicle line that produces only one specification. . Moreover, although only one vehicle type was produced in one vehicle line, it is not restricted to this, It is also possible to apply this invention to the vehicle line which produces several vehicle types.
In the present embodiment, only one unit type is produced in one unit line. However, the present invention is not limited to this, and the present invention can be applied to a unit line producing a plurality of types of units. It is.
In addition, the technical elements described in the present specification or the drawings exhibit technical usefulness alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the technology illustrated in the present specification or the drawings achieves a plurality of objects at the same time, and has technical utility by achieving one of the objects.
[Brief description of the drawings]
FIG. 1 is a diagram illustrating a relationship among product types, functional components, and component types.
FIG. 2 is a diagram showing a system configuration of a production number planning apparatus.
FIG. 3 is a diagram illustrating a data configuration example of order information.
FIG. 4 is a diagram illustrating a data configuration example of vehicle line information.
FIG. 5 is a diagram showing a data configuration example of vehicle line / vehicle type / specification / required production quantity information;
FIG. 6 is a diagram illustrating a data configuration example of unit line information.
FIG. 7 is a diagram illustrating a data configuration example of lead time information.
FIG. 8 is a diagram illustrating a back eye adjustment example.
FIG. 9 is a diagram illustrating an example of subtraction adjustment.
FIG. 10 is a diagram showing a data configuration example of production plan number information by vehicle type / specification.
FIG. 11 is a flowchart illustrating a production number plan planning process.
FIG. 12 is a flowchart showing a production number plan planning process.
FIG. 13 is a flowchart showing a production number plan planning process.
FIG. 14 is a diagram for explaining the outline of the present invention;
FIG. 15 is a diagram illustrating an outline of the invention.
FIG. 16 is a diagram for explaining the outline of the present invention;
[Explanation of symbols]
2: Overseas sales department supervising computer,
4: Domestic sales department head computer
6: Production number planning device,
8: Order information reception / aggregation means,
10: Vehicle line / vehicle type / specification / required number of vehicles calculation means
12: Unit line / unit function / type / production plan number calculation means,
14: Vehicle line / vehicle type / specification / production plan number subtraction adjustment means,
16: Production plan number calculation means by vehicle type / specification / unit function / type,
18: Response information transmission means,
32: Order information storage means,
34: Vehicle line information storage means,
36: Vehicle line / vehicle type / specification / necessary production quantity information storage means,
38: Vehicle type / specification / unit type combination information storage means:
40: Unit line information storage means,
42: Lead time information storage means,
44: Shipping / shipping frequency information storage means,
46: Line working day information storage means,
48: Vehicle line / unit function / type / safety stock quantity information storage means,
50: Unit line / unit function / type / stock quantity information storage means,
52: Previous vehicle line / vehicle type / specification / production plan number information storage means,
54: Unit line / unit function / type / production plan number information storage means,
56: Production plan number information storage means by vehicle type / specification / unit function / type,

Claims (5)

Equipped with multiple parts production lines and multiple product production lines, supplying parts produced in one parts production line to multiple product production lines, combining multiple parts with different functions to produce products, and having the same function An apparatus for creating a production number plan for each product type for a production system that creates a product type by changing the combination of the component types by selecting from a plurality of component types,
“Order source / product type / number of orders” counting means for counting the number of orders by order source / product type;
"Product type / part type combination" storage means for storing combinations of component types used for the product type for each product type;
"Product production line / product type / number of products that can be produced / priority" storage means for storing the product types that can be produced in each product production line, the number of products that can be produced, and the priority order for the order source;
“Parts production line / part type / number of producible / priority” storage means for storing the types of parts that can be produced in each part production line, the number of products that can be produced, and the priority order for the product production line;
"Parts production line / product production line / lead time" storage means for storing the lead time from each part production line to each product production line;
“Order source / product type / number of orders” totaling means totaled by order source / product type and products stored in “product production line / product type / number of producible / priority” storage means “Product production line / product type / necessary number of production” calculation means for calculating the production required number for each product production line / product type based on the priority for the production line, product type, production possible quantity and order source;
The product type stored in the “product type / part type combination” storage means based on the required number of products by product production line / product type calculated by the “product production line / product type / number of production required” calculation means And the combination of the part type, the part production line stored in the "part production line / part type / number of producible / priority" storage means, the part type, the number of producible products, the priority for the product production line, Refer to the lead time from each part production line to each product production line stored in the “Production line / Product production line / Lead time” storage means, and production by period / part production line / part type is necessary. “Period / part production line / part type / production required number” calculating means for calculating the number,
The required number of production by period / part production line / part type calculated by the “period / part production line / part type / number of production required” calculation means is “part production line / part type / manufacturable number / priority”. ”Reduce the production plan number of the part type exceeding the production possible number for each part type stored in the storage means to the production possible number or less, and within the range of the reduction number, the period corresponding to the reduced period Calculate the number of production plans by period / part production line / part type by increasing the number of production plans for other part types of the same functional part within the range of production possible. Line / part type / number of production plans ”calculating means,
Based on the number of production plans for each period / part production line / part type calculated by the "period / part production line / part type / production plan number" calculation means, the "product type / part type combination" storage means stores Refer to the combination of the product type and the part type being used and the lead time from each part production line to each product production line stored in the "part production line / product production line / lead time" storage means, “Product type / Production plan number” calculating means for calculating the number of production plans by product type,
To calculate "period / part production line / part type / production plan number"
(1) Reduced the number of production plans for the part types of other functional parts included in the product type, which includes the part type whose production plan number has been reduced from the required number of products in the "product type / part type combination" In the period corresponding to the period, decrease in conjunction,
(2) Increased the number of production plans for the part types of other functional parts included in the product type, which includes the part type whose production plan number is increased from the required number of productions in the "product type / part type combination" Production by product type, characterized in that in the period corresponding to the period, linked adjustment means is added to execute processing to increase the number of parts production lines that produce the part type in conjunction with the upper limit. Number planning device. The “order source / product type / number of orders” counting means recalculates the number of orders by order source / product type every predetermined period,
The “Product Production Line / Product Type / Production Required Number” calculation means recalculates the production required number for each product production line / product type for each predetermined period,
The number of production plans by product production line for product types that use part types whose required number of production exceeds the number that can be produced is calculated this time, and the number of production plans by product production line / product type calculated previously. The ratio of difference between the required number of production by product production line / product type is reduced from the required number of production by product production line of the product type according to the ratio of total difference ratio of all product production lines. "Product production line / number of production plans" reduction adjustment means to be added,
2. The planning apparatus according to claim 1, wherein the “product type / number of production plans” calculation means recalculates the number of production plans for each product type every predetermined period. The number of production plans for each product production line of a product type that uses a part type for which the required number of production exceeds the production possible number, and the required number of production for each product production line of the product type that uses that part type According to the ratio of the total production requirement, reduce the difference between the production requirement number of the relevant part type and the production plan number from the production requirement number for each product type by the product production line / 2. The planning apparatus according to claim 1, further comprising means for adjusting the number of production plans to be reduced. Equipped with multiple parts production lines and multiple product production lines, supplying parts produced in one parts production line to multiple product production lines, combining multiple parts with different functions to produce products, and having the same function A method for creating a production number plan for each product type for a production system in which a product type is created by changing a combination of component types by selecting from among a plurality of component types, and includes the following steps by a computer: That is,
A process of aggregating the number of orders by order source / product type;
Reading the combination of parts types used for each product type by product type,
The process of reading the product types that can be produced on each product production line, the number of products that can be produced, and the priority order for the order source,
Reading the types of parts that can be produced in each part production line, the number of products that can be produced, and the priority order for the product production line,
The process of reading the lead time from each part production line to each product production line,
Calculating the required number of production by product production line / product type based on the number of orders by order source / product type, the product production line, product type, production available number, and priority to the order source;
Based on the required number of production by product production line / product type, combination of product type and part type, part production line, part type, number of products that can be produced, priority for product production line, and each product Referring to the lead time to the production line, calculating the required number of production by period / part production line / part type,
The number of required production by period / part production line / part type exceeds the production plan for parts types that exceed the production capacity by part type, and within the range of reductions. In the period corresponding to the decreased period, the production plan by period / part production line / part type is increased by increasing the number of production plans of other part types of the same functional part within the range of the production possible number. Calculating the number;
Based on the number of production plans by period / part production line / part type, refer to the combination of product type and part type and the lead time from each part production line to each product production line. A process for calculating the number of production plans,
In the process of calculating the number of production plans by period / part production line / part type,
(1) A period corresponding to the period when the number of production plans for the part type of other functional parts included in the product type includes the part type whose production plan number is reduced from the required number of productions in the combination of the part type. In conjunction with,
(2) A period corresponding to the increased period of the number of production plans for the part types of other functional parts included in the product type that includes the part type with the number of production plans increased from the required number The method of creating a production quantity plan for each type of product, characterized in that a process for increasing the number of parts that can be produced on the part production line in association with each other is executed. Equipped with multiple parts production lines and multiple product production lines, supplying parts produced in one parts production line to multiple product production lines, combining multiple parts with different functions to produce products, and having the same function A program for creating a production number plan for each product type for a production system in which a product type is created by changing the combination of the component types by selecting from among a plurality of component types, Processing, i.e.
Totaling the number of orders by order source / product type,
Processing to read the combination of the parts types used for each product type by product type,
A process for reading the types of products that can be produced on each product production line, the number of products that can be produced, and the priority order for the order source,
A process for reading the type of parts that can be produced in each part production line, the number of products that can be produced, and the priority order for the product production line,
Processing to read the lead time from each part production line to each product production line,
A process for calculating the required number of products by product production line / product type based on the number of orders by order source / product type, the product production line, the product type, the number of products that can be produced, and the priority for the order source;
Based on the required number of production by product production line / product type, combination of product type and part type, part production line, part type, number of products that can be produced, priority for product production line, and each product from each part production line With reference to the lead time to the production line, the process of calculating the required number of production by period / part production line / part type,
The number of required production by period / part production line / part type exceeds the production plan for parts types that exceed the production capacity by part type, and within the range of reductions. In the period corresponding to the decreased period, the production plan by period / part production line / part type is increased by increasing the number of production plans of other part types of the same functional part within the range of the production possible number. Processing to calculate the number;
Based on the number of production plans by period / part production line / part type, refer to the combination of product type and part type and the lead time from each part production line to each product production line. Process to calculate the number of production plans,
In the process of calculating the number of production plans by period / part production line / part type,
(1) A period corresponding to the period when the number of production plans for the part type of other functional parts included in the product type includes the part type whose production plan number is reduced from the required number of productions in the combination of the part type. In conjunction with,
(2) A period corresponding to the increased period of the number of production plans for the part types of other functional parts included in the product type that includes the part type with the number of production plans increased from the required number , A program for drafting a production quantity plan for each type of product, wherein a process for increasing the number of parts that can be produced on the part production line is executed in conjunction with each other.

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